Wdr505 Underground Cable Pulling Trailer
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
USER'S GUIDE & SAFETY MANUAL
USER'S GUIDE & SAFETY MANUAL
WDR505 Underground Pulling Trailer
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Important Safety Notice Read and understand all procedures and safety instructions before using a Condux Underground Pulling Trailers. Observe all safety information on this page and note specific safety requirements as explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.
ADVERTENCIA: Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud. no comprende las instrucciones favor de consultarle a su jefe.
Save this user’s guide for future reference.
COMMUNICATIONS WITH THE MANUFACTURER: For information related to the machine (use, maintenance, spare parts) always-state model number, manufacturing Year and Order. This date can be found on the parts identification label. Manufacturer: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56002-0247 1-507-387-6576 Fax 1-507-387-1442 E-mail: [email protected]
If you have questions on: SAFETY - OPERATIONS - APPLICATIONS CALL 1-800-533-2077 2
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Table of Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 A. Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 B. Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 C. Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 A. Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 B. Emergency Stop Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 C. Periodic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 D. Cautions & Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 E. Pulling Rope Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 F. Rotating Component Pinch-Point Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 G. Crushing Injury when Loading or Unloading Rope or Conductor Reels . . . . . . . . . . . .8 H. Electrostatic Discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 I. Inhalation Engine Exhausting Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 A. Machine Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 B. Packing for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 C. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 D. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 5 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 A. Positioning the Trailer & Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 B. Stabilize Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 C. Start Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 D. Payout Winch Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 E. Prepare for Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 F. Electronic Control Box (ECB) Set-up (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 G. Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 H. Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A. General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 B. Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 C. Suggested Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 D. Hydraulic Circuit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 E. Reduction Unit and Reel Winder Negative Brake Maintenance . . . . . . . . . . . . . . . . . .14 F. Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 G. Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 H. Electronics Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 I. Summary Table for Ordinary Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 J. Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Troubleshooting 7 8 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 A. Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 B. Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 C. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 D. Suggested Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 E. Parts Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 9 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 10 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
3
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
1.
www.comstarsupply.com
General Information PRODUCT DESCRIPTION
The WDR505 pulling trailer provides up to 11,240 lbs. of pulling force and a max speed of 219 ft/min. It comes equipped with a digital meter counter, hydraulic dynamometer with set point and automatic control of the maximum pull, a noise reduction kit, as well as 1,640 feet of anti-twist rope a key feature. Anti-twist rope offers high flexibility, complete stability to rotation and increased efficiency during pulling operation. An optional Electronic Control Box to monitor pulling speeds and tension is available, as well as an extension arm with multiple pulling positions to accommodate most applications. Condux International manufactures a complete line of cable installation tools and equipment. SAFETY INFORMATION • Only trained and qualified operators should use this machine. • Qualified operators are those persons who have received training from the machine owner’s company or, alternatively, from the manufacturer. • This machine must be used only for the work it was designed for. • This machine should not be used with unauthorized personnel on the work site. • For any questions regarding operation, function, maintenance, etc., contact the After-sales Service of the manufacturer. OPERATOR INFORMATION • Operators must be aware of all local, state and federal safety regulations governing the use of this equipment. • Operators must wear suitable clothing to reduce the possibility of entanglement in the machine’s moving parts. They should avoid the wearing of chains, and other jewelry for the same reason. • Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.). • Operators must carefully follow hazard related instructions contained in this instruction manual or indicated on the machine. • This machine’s work area should be free as possible of oil or other liquid spills as well as materials or equipment that may be considered as an obstacle to proper operation. • The operator must absolutely avoid the direct inhalation of the system’s engine exhaust gas. GENERAL MAINTENANCE INFORMATION
4
• It is absolutely forbidden to carry out any maintenance, or adjust any settings on this machine while pulling (except for those indicated in this manual). • Before carrying out any maintenance stop the engine (except for those instances indicated otherwise in this manual) and wait till the system components subject to heating have cooled sufficiently • All the maintenance performed on this machine must be carried out on a level surface and while the system is not under load. • Authorized and trained personnel must perform all of the maintenance, both scheduled maintenance and repair. Authorized and trained personnel are those persons who have received training on the maintenance of this equipment from the machine owner’s company or, as alternative, from the manufacturer. • Maintenance personnel must wear suitable clothes to reduce the possibility of entanglement in the machine’s moving parts. They should avoid the wearing of chains, and other jewelry for the same reason. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
• Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.). • All maintenance operations, both scheduled and repair, must be carried out per the instructions included in this manual or following technical instructions provided by the manufacturer. Failure to follow these instructions relieves the manufacturer from any responsibility and voids their warranty. MACHINE USAGE The machine must not be used: • For lifting persons and/or goods • In a location where the machine can not be positioned and anchored in a proper way • In areas with brush or other materials that can be easily set on fire • In closed/unventilated sites or those poorly ventilated (tunnel or similar) • At sites where fuels or explosives are present • For structure demolition • For the pulling of elastic elements • With ropes or joints having a bigger diameter than that specified in this manual • With over-ridden or broken safety system devices • For handling trucks or other movable equipment RESPONSIBILITY Use of the machine in situations different from those indicated in paragraph 2.3 (Typology and using field), or those not described in this manual, is to be considered extremely dangerous and/or forbidden. Persons not using recommended restraints cause a situation of improper use, and relieve the manufacturer from any responsibility for accidents, injuries to persons or damage to property. The manufacturer’s warranty is also voided. Similarly the manufacturer’s responsibility ends when the following situations occur: • Tampering and/or modifying of the system without the manufacturer’s written acceptance (in this case the operator becomes the manufacturer assuming all obligations and responsibilities, both civil and penal). • The use of non-original spare parts. • Poor maintenance. • Use with disconnected or over-ridden safety devices. • For the connection to machine and/or plans not produced and not directly authorized by the manufacturer in a written acceptance. OPERATORS MANUAL • Information contained in this manual applies to all the operators charged with the use and/or the maintenance of the machine. • This instruction manual is not a training manual. • Before using the machine the job site supervisor and the operators must read this instruction manual. • The supervisor is obliged to inform all operators about the instructions contained in this manual. • All operators user must carefully follow the instructions contained in this manual. • Before using the machine the operator must know the positions and the operation of all the controls. • The job site supervisor must verify that the instructions contained in this manual are applied. • This instruction manual must be kept with the machine, for the entire life of the machine, so it is available to all potential users and operators. • The instruction manual must be kept in a sheltered and dry place. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
5
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
4.
2.
www.comstarsupply.com
Technical Specifications
The Condux WDR505 Hydraulic Underground Pulling Trailer provides up to 9,000 lbs of continuous pulling force. Designed for installing underground cable, the WDR-505 is completely self-contained and transports easily from jobsite to jobsite. Industry leading features like antiwist rope and modular extension arms make the WDR-505 the most advanced puller in the market today. An advanced electronic information system is also available for monitoring and documenting vital pulling functions. GENERAL SPECIFICATIONS PULLER MAX LINE PULL, POUNDS
11,250
SPEED AT CONTINUOUS PULL, POUNDS
9,000
HIGH SPEED CONTINUOUS PULL, POUNDS
2,250
PULLING SPEED FEET PER MINUTE
0–219
BULL WHEEL DIA., INCHES
13
MAX ROPE DIA., INCHES
9/16
FEET OF ROPE
2,300
ENGINE TYPE
DIESEL 46
HORSEPOWER ELECTRICAL SYSTEM
12 Volt
A. OPERATIONAL CONDITIONS Temperature: from -10°C to +40°C. Relevant moisture: from 30% to 90% ± 5%. Weather conditions: any (in line with working conditions). Natural and/or artificial lighting of the working site. B. HYDRAULIC OIL When using the machine always keep in mind operating conditions and their effect on the possibility of your exceeding the following temperature limits for the system’s hydraulic oil. TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C) Hydraulic oil viscosity
Working condition
ATF oil
VG 22
VG 32
VG 46
VG 68
Minimum temperature running in neutral position
-15
-21
-14
-7
-1
Minimum temperature running in full load
19
8
16
24
32
Maximum temperature running in full load
66
48
57
67
76
Maximum temperature running in neutral position
84
63
73
83
93
For additional information concerning the hydraulic oil, see chapter “Maintenance” and the attached comparative table of the oils used on the machine. C. NOISE EMISSION Level of acoustic power (2000/14/CE) LwA = 102 dB(A) Maximim sound pressure level to the operator seat (ISO 11202 – December 1995) Lep = 83 dB(A)
6
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Safety Information
3.
3.
A. SAFETY DEVICES
Machine has been equipped with the following safety devices: • A load-limiting device that automatically stops the engine once the max. pre-set load value has been exceeded • A mechanical negative safety brake that stops all movement if hydraulic pressure is lost • Where possible, guards and covers are provided to protect personnel from moving parts
!DANGER: it is absolutely forbidden to use this machine with protective guards removed or with damaged or disconnected safety devices. B. EMERGENCY STOP DEVICE An emergency stop button is provided (Figure 1) on the control panel. Pushing it immediately stops the engine.
!CAUTION: Use of the emergency stop is ONLY recommended in emergency situations. It is NOT recommended to use the emergency stop system for normal shut down of the system. C. PERIODIC OPERATIONS Proper functioning of safety systems should be verified daily.
!CAUTION: Any customer alterations to the provided safely devices relieves the manufacturer of any responsibility Figure 1. Emergency Stop Button for any resulting damage of property or injury to personnel. D. CAUTIONS & WARNINGS When operating this machine users must be aware of other risks associated with the work for which the machine is intended.
E. PULLING ROPE FAILURE Obviously this will cause uncontrolled movement of the entire machine. Both this and the danger then presented by the pulling rope and/or conductor can cause serious injury or death. To reduce operator exposure to these dangers owners must: • Regularly check the rope and replace it as soon as defects or signs of wear are detected • Assume only the recommended operation positions indicated in this manual
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
7
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
F. ROTATING COMPONENT PINCH-POINT HAZARDS Due to the nature of the work being performed and important system functionality, it is not possible to fully guard all rotating components. To minimize risks operators must: • Avoid any contact with the machine’s rotating components • Follow the anchoring instructions described in this manual • Follow all recommendations in this manual regarding the use of personal safety equipment
G. CRUSHING INJURY WHEN LOADING OR UNLOADING ROPE OR CONDUCTOR REELS Operators must know the proper methods for executing these tasks and should be trained to do them properly.
H. ELECTROSTATIC DISCHARGES To reduce the risk presented by static electric charge build up in the ropes and conductors during pulling operations, the machine must be properly grounded. To minimize these risks operators must: • Be trained in, and apply, the proper methods used to ground the machine during before using the machine.
I. INHALATION ENGINE EXHAUSTING GAS To minimize these risks operators must: • Assume the proper operating position during operation and use appropriate safety equipment as needed
8
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Transporting A. MACHINE LIFTING
For machine lifting use only devices (overhead traveling cranes, lift trucks, ropes, cables, hooks, etc.) with a capacity equal to the weight to be lifted. Personel should not be on the machine when it is lifted.
!DANGER: Failure to follow the recommendations in this section may create a dangerous situation and/or damage to the machine. The manufacturer’s warranty may also become void as a result.
3.
4.
B. PACKAGING FOR SHIPMENT Transport by land by truck Certain surfaces may be protected by cardboard and/or plywood and/or polyethylene film. To prevent movement, use nailed wheel chocks. Attach the machine to the floor of a truck box or trailer using chains and hooks at the attachment points provided. C. UNPACKING When receiving the machine verify the condition of the package; immediately notify the transportation company and the manufacturer (use photos whenever possible) of any damage that may have occurred during shipment. Verify that the supplied product matches that which was ordered; immediately advise the manufacturer if there is a discrepancy. Use caution when unpacking to avoid damaging the product.
!CAUTION: Disposal of all packaging materials must be in accordance with local regulations. D. TOWING This machine is designed for towing at highway speeds. No personnel may ride on the machine at any time while towing the machine at ANY speed.
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
9
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
5.
5.
www.comstarsupply.com
Operating Procedures
It is essential that the Underground Pulling Trailer be properly set up before operation. Using the following procedure will allow the unit to be set up in a short period of time and yield optimum performance.
A. POSITIONING THE TRAILER & LOWER BOOM Position the WDR 505 Puller within an approximate boom arm reach of the manhole or duct bank. After trailer is positioned, lower boom arm. NOTE: It may be necessary to payout a small amount of winch line (releasing it from the boom) first to allow the boom to be lowered. If so please refer to Steps C and D before proceeding. Remove the traveling pin and carefully lower the boom to the position desired for pulling operations (Figure 2). Once in position lock the boom in place with the pin (Figure 3).
Figure 2. Remove Traveling Pin
Figure 3. Lock Boom in Place
Now that the boom is in place, minor adjustments in the puller’s position can be made if necessary for optimum working alignment.
B. STABILIZE TRAILER After the WDR 505 is properly positioned, place wheel chocks to prevent trailer movement. NOTE: The trailer may be disconnected from the tow vehicle or left connected depending on specific site conditions. After placing wheel chocks, stabilize the trailer using three of the five supplied adjustable leveling jacks. Place three jacks in the jack mount locations on the trailer. Raise and lower jacks by rotating crank handle (Figure 4). Place two jacks on the boom arm and adjust jacks until the boom arm is level to the ground (Figure 5). 10
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Figure 4. Rotating Crank Handle Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Figure 5. Boom Arm Level to the Ground
C. START PULLER Open control panel on side of WDR 505 and secure. Start the engine by holding the glow plug rocker switch unit the glow plug indicator light goes out (Figure 6). Turn the ignition key while holding the glow plug rocker switch until the OK light comes on (Figure 7). Adjust the throttle so the engine runs at a medium RPM.
Figure 7. Turn Ingition Key while Holding Rocker Switch
Figure 6. Hold Glow Plug Rocker Switch
D. PAYOUT WINCH LINE Payout the winch line by pushing the winch line joystick up. The joystick is infinitely variable so payout speed can be varied by the degree to which the joystick is moved. IMPORTANT: Always keep tension on the winch line when paying it out to prevent slack from developing in bull wheel. In typical applications, the winch line will need to be paid out to reach the work area first, i.e. manhole, duct bank, etc. Then prepped for pullback, ie, pulled through duct bank with a pulling rope or tape or installed with a Condux Winch Line Blower. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
11
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
E. PREPARE FOR PULLBACK Verify that reel winder pressure gauge is reading between 580 and 870 PSI. If the gauge is reading higher or lower adjust by turning the pressure adjust knob until pressure reads between 580 and 870 (Figure 8). Adjust Maximum Tension Limiter to desired maximum pulling tension value (measured in tons) by inserting the black removable knob into the center of the large dial. Press down on the block knob and rotate until the large red needed is adjusted to the desire value. This will be the maximum pulling force the machine will exert. Once the limit is reached the entire system will shut down and a warning sound will be activated. (Figure 9).
Figure 9. Adjust Maximum Tension Limiter
Figure 8. Verify Reel Winder Pressure Gauge Set hydraulic fluid cooling fan. In the manual mode the fan will remain on at all times. In automatic mode the fan will only come on when the system reaches a temperature of 122°F (Figure 10). NOTE: It is recommended to keep the fan in manual mode if the air temperature is 85 degrees or higher. For automatic mode, turn the fan switch to the (circle symbol) position. For manual mode, switch fan selector to the (circle w/ line symbol) position. NOTE: The red fan indicator light will be lit when fan is in operation.
Figure 10. Set Hydraulic Fluid Cooling Fan
F. ELECTRONIC CONTROL BOX (ECB) SET-UP (OPTIONAL) If the WDR 505 is equipped with an ECB, set ECB parameters at this time. Refer to WDR 505 Quick Reference Guide Section - DLR100 Programming and Set Up for ECB set up instructions.
12
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G. PULLBACK To start pullback, pull winch line joystick down. The speed of the pullback can be increased by increasing the throttle. During pullback make sure to monitor pull force and speed.
H. SHUT DOWN At the end of the pull, relieve pulling rope tension using the control lever. Turn off ignition key.
Maintenance
3.
6.
A. GENERAL PROCEDURES !CAUTION: Any customer repairs not authorized by the manufacturer relieves the manufacturer of any responsibility for any resulting damage of property or injury to personnel. B. FLUID LEVELS Due to safety and/or regulatory reasons, this machine may arrive without hydraulic oil and fuel. Fill the levels as per the following table: Fluids
Quantity
Hydraulic oil level (table 1, pos. 1)
100 l – 26.4 gal
Engine oil level (see enclosed engine booklet) Fuel level (table 1, pos. 4)
28 l – 8 gal
Negative brake for bull-wheel oil level (table 1, pos. 8)
0.3 l – 0.08 gal
Negative brake for reel winder oil level (table 2, pos. 3)
0.4 l – 0.1 gal
!CAUTION: Not filling fluids to those levels specified above will cause serious damage to system components and voids all product warranties. !DANGER: Purposely ingesting hydraulic liquids, fuels and cooling liquids is potentially lethal. C. SUGGESTED LUBRICANTS The manufacturer tests the machine with the following oils and lubricants: hydraulic circuit and negative brake: IP HYDRUS OIL 46 (ISO VG 46). Alternates must be chosen from the enclosed table “SUGGESTED LUBRICANTS”. It is possible to use different products, but they must have the same characteristics and ISO specifications.
!CAUTION: The use of lubricants not in conformity with the technical specifications indicated in the referenced table can seriously damage the machine, its components and voids all product warranties.
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!DANGER: Let the engine cool prior to performing any maintenance, or before refueling. D. HYDRAULIC CIRCUIT MAINTENANCE Change the hydraulic oil after 500 working hours, then every 1500 hours (or at least annually). To drain the hydraulic oil remove the hydraulic tank’s drain plug (table 2, pos. 6).
!DANGER: Allow the hydraulic oil to completely cool before removing it. Always use suitable safety gear (gloves, etc.). !CAUTION: Disposal of all drained system oils and fluids must be in accordance with local regulations. Fill the hydraulic oil using the filler spout designated on table 1, pos. 2.
!CAUTION: insure that no foreign matter enters the system along with the oil; if possible filter the oil with a 10 µm filter. Replace the filter cartridge after 500 working hours and then, every 1500 hours (or at least annually). Check that the hydraulic oil filter lamp lights only during start-up. If lit ant any other time it indicates that the hydraulic oil filter needs replacing. For further maintenance instructions on the hydraulic components (pumps and motors) refer to the enclosed documentation.
E. REDUCTION UNIT AND REEL WINDER NEGATIVE BRAKE MAINTENANCE Change the oil of the bull-wheel reduction unit and negative brake (table 1, pos. 8) and of the reel winder brake after 50 working hours and, thereafter, every 500 hours (or at least annually). To drain the reduction unit and negative brake’s oil use the plugs on the lower part of their housings.
!DANGER: Allow the oil to completely cool before removing it. Always use suitable safety gear (gloves, etc.). !CAUTION: Disposal of all drained system oils and fluids must be in accordance with local regulations.
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Fill the oil into the reduction unit and in the negative brakes using the proper fill spout
!CAUTION: insure that no foreign matter enters the system along with the oil. For further maintenance instructions on these subsystems (reduction gear, negative brakes) refer to the enclosed documentation.
F. OIL MAINTENANCE At least once a year, or as frequently as required, using compressed air, blow all debris from the fins of the oil coolers.
!CAUTION: Personnel cleaning the oil coolers as per above should wear all required personal protective gear, including a respirator. G. GREASING The crown gear of the bull-wheels should be greased 2-3 times per day using the proper grease. Grease all the other points not automatically lubricated daily. Use IP ATHESIA GR2 (ISO XBCEA 2) grease or equivalent from the enclosed “SUGGESTED LUBRICANTS” table.
H. ELECTRONICS NOTE When cleaning the machine, avoid direct spraying of water or steam on electronic components or the control panel. For the other periodic operations refer to the summary table for the ordinary maintenance (see next page).
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I. SUMMARY TABLE FOR ORDINARY MAINTENANCE This table lists the recommended service intervals for the systems noted. Part
Object
Diesel engine
Engine oil
Interval Daily
50 h
CL
ST
Cooling liquid
CL
ST VF
Air filter Fuel
Bull-wheel gear box
Reel winder
ST
CL
Fuel filter
ST
Hydraulic oil
CL
ST1
ST(*)
Filter
VF
ST1
ST(*)
Oil
CL
ST1
ST(*)
CL
ST1
ST(*)
CL
ST1
ST(*)
Bull-wheel negative Oil brake Reel winder negative Oil brake Bull-wheels greasing circuit
1500 h
ST
Oil filter
Hydraulic circuit
250 h 500 h
Gears
GR
Chain transmission Level winder screw
GR GR
Pawl
VF
Legend: CL Check the level (and possible filling up) GR Grease ST Replace ST1 Replace (only for the first time) VF Check (*) Or in any case every year
J. EXTENDED STORAGE When an extended storage period is anticipated (two months or more) coat external parts with waterproof protectant. During the storage period, start the machine at least once every two months and let the engine idle for approx. one hour. Do this so that oil enters the hydraulic system and coats all gaskets, o-rings, etc. The machine should be stored under a roof. Do not tarp the machine as excess moisture may collect under it and cause damage to the system. If the machine is stored for a year or more, replace the hydraulic circuit’s oil and filters prior to startup.
16
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Troubleshooting Guide PROBLEM:
CAUSE:
SOLUTION:
Burned fuse
Replace
Ran down battery
Recharge or replace
Disconnected contacts of the The diesel engine starter ignition system / starter doesn’t work. Oxidised contacts of the ignition system / starter
Diesel engine doesn’t work.
3.
7.
Reconnect Clean or spray with a suitable vaporiser
Starter out of order
Replace / Technical assistance
The emergency pushbutton is pushed in locked position
Release
The ignition push-button is not pushed
Push the ignition pushbutton and keep it pushed till the engine starts
Wait for the turning off The pre-heating glow plugs of the pre-heating glow warning light isn’t turned off plugs warning light Fuel problem
Check the fuel level in the tank Check the fuel filter Add engine oil
Check of the engine oil pressure
Defective sensor– check contacts / replace Engine anomaly – technical assistance
Diesel engine turns off when releasing the ignition push-button.
Add cooling liquid Defective sensor– Check of the engine cooling check contacts / liquid temperature replace Engine anomaly – technical assistance
The feeding pressure is lower than 24 bar – 340psi
Clogged hydraulic oil filter
Replace
Defective pump
Technical assistance
Diesel engine doesn’t increase rpm
Disconnected accelerator cable
Verify and if necessary replace
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PROBLEM:
CAUSE:
SOLUTION:
Hydraulic oil temperature too low
Wait for a few minutes for heating the oil without speed up the diesel engine. It is possible to reduce the oil heating time by turning off the fan of the hydraulic oil radiator (if turned on) and by closing the reel winder valve at 50 bar – 725 psi
The oil is too thick as regards as the environmental conditions
Use oil with lower viscosity as per the indications in the instruction manual
Clogged hydraulic oil filter
Replace
Disconnect joy-stick contacts
Reconnect
Oxidised joy-stick contacts
Clean or spray with a suitable vaporiser
The clogged filter warning light turns on.
Verify the intervention and the electric contacts of the negative brake opening solenoid valve
When starting the control lever the bullwheels don’t work.
The negative brake on the reduction unit doesn’t open Disassemble the brake and verify if the brake discs are in locking position – technical assistance
The electronic card for pump control doesn’t work
Defective pump servo control
18
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Verify the ignition of the green and red LEDS on the card by moving the joy-stick – if the LEDS don’t turn on, replace the fuse on the card or verify the joy-stick potentiometer – technical assistance Verify the electric contacts – technical assistance
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CAUSE:
SOLUTION:
Increase the reel winder pressure Reel winder pressure not sufficient
Replace the adjusting valve for the reel winder pressure Reel winder pump problem – technical assistance
When moving the control lever, the bullwheels rotate but the rope doesn’t move – slips on the bullwheels. The negative brake on the reel winder doesn’t open
Verify the intervention and the electric contacts of the negative brake opening solenoid valve Disassemble the brake and verify if the brake discs are in locking position – technical assistance Add engine oil
Check of the engine oil pressure
Defective sensor – check contacts / replace Engine anomaly – technical assistance Add cooling liquid
Defective sensor Check of the engine cooling – check contacts / Diesel engine turns off liquid temperature replace during operations. Engine overheating – technical assistance The max. pre-set pull has been reached
Intervene of the pull limiting device on the dynamometer Increase the intervene threshold of the pull limiting device Operation of the emergency Release push-button
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PROBLEM:
The machine doesn’t reach the max. pull performances.
CAUSE:
SOLUTION:
Diesel engine rpm not sufficient
Speed up the engine
Diesel engine decreases rpm and turns off
Decrease the control lever capacity
Excessive hydraulic oil temperature
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm Check the fuel filter
Insufficient fuel feeding at diesel engine
The machine doesn’t increase speed.
Fuel feeding system to be adjusted – Technical service
Diesel engine rpm not sufficient
Speed up the engine
Diesel engine decreases rpm and turns off
Decrease the control lever capacity – the applied pull doesn’t allow to reach higher speed
Excessive hydraulic oil temperature
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm Check the fuel filter
Insufficient fuel feeding at diesel engine
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Fuel feeding system to be adjusted – Technical service
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CAUSE:
SOLUTION:
The fan of the hydraulic oil doesn’t work
5 Blue Heron Drive
Verify the electric contact of the ventilator ignition selector on the control panel
Overused machine
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm
Anticipated closing of the negative brake
Verify the control by means of the suitable trimmer on the electronic card
Hydraulic pump with defective zero setting
Carry out the hydraulic and mechanic zero setting – technical assistance
Excessive hydraulic oil temperature.
An anomalous stop happens when returning to center position with the control lever
Verify the electric contact of the temperature bulb on the radiator
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11.
8.
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Appendices QUICK REF. SERVICE & PARTS LIST A. HYDRAULIC OIL FILTERS Manufacturer
Part Number
Quantity
Vendor
Alternative Vendors
MP Filtri
CS-150-P10-A
1
Motion Industries
Filtrec A121C10
B. ENGINE AIR FILTER Manufacturer
Part Number
Quantity
Vendor
Cummins
1236-01-00
1
Cummins
C. ENGINE Manufacturer
Engine Model
Cummins
A2000
Engine Service Part
Part Number
Oil filter
LF-16034
Fuel Filter
FS-1235
Fan Belt
4900271
Lubricants
Specification (*)
Engine Oil
SAE 15w-40
Hyd. Fluid
ISO 32
Gear Lube
ISO 150
General Grease
EP 2
* See Engine Manual or Recommended Lubricants chart for temperature variances. Ø All filters, parts, and service for the engine can be found at your local Cummins distributor. Your local distributor can be found at: Cummins, Inc. 1-800-DIESELS (1-800-343-7357) USA & Canada only
22
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DONAX TM
ATF 200
MOBIL
SHELL
DEXRON II
VG 33-VG 39
UNIVERSAL OIL ATF
CASTROL
(ISO 3448)
VISCOSITY
TYPE
TELLUS 22
TELLUS 32
DTE 24
HYSPIN AWS 32
HYSPIN AWS22
DTE 22
VG32
-10°C
-30°C
VG22
COLD
ARCTIC
VG68
TROPICAL 40°C+
VG100
-30°C VG150
-10âC
COLD
TELLUS 46
DTE 25
HYSPIN AWS 46
TELLUS 68
DTE 26
HYSPIN AWS 68
OMALA 150
MOBILGEAR 629
MOBILGEAR 627 OMALA 100
ALPHA SP 150
ALPHA SP 100
OMALA 220
MOBILGEAR 630
ALPHA SP 220
VG220
30°C
TEMPERATE
GEAR BOX
SUGGESTED GENERAL MANUFACTURERS
VG46
30âC
TEMPERATE ARCTIC
SUGGESTED LUBRICANTS
HYDRAULIC CIRCUIT AND STATIONARY BRAKE
D. SUGGESTED LUBRICANTS
OMALA 320
MOBILGEAR 632
ALPHA SP 320
VG320
40°C+
TROPICAL
SUPERGREASE EP 2
MOBILUX EP 2
SUPERGREASE 2
EP 2
EP TYPE
GREASE
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C. PARTS BREAKDOWN
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Notes
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3.
9.
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Warranty Information
3.
10.
A. FACTORY ASSISTANCE
Condux International can provide further advice regarding any problems with the installation, service, assembly, or disassembly of the Condux Underground Puller. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Condux Underground Puller can be returned to the factory at any time for service or repair; however, a Return Material Authorization (RMA) must be obtained from Condux before shipping. Condux will not accept returned items without an RMA.
B. LIMITED WARRANTY Condux International, Inc. extends the following warranty to the original purchaser of these goods for use, subject to the qualifications indicated: Condux International, Incorporated warrants to the original purchaser for use that the goods or any component thereof manufactured by Condux International will be free from defects in workmanship for the period of one year from the date of purchase, provided such goods are installed, maintained, and used in accordance with Condux’s written instructions. Components not manufactured by Condux International but used within the assembly provided by Condux International are subject to the warranty period as specified by the individual manufacturer of said component, provided such goods are installed, maintained, and used in accordance with Condux’s and the original manufacturer’s written instructions. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising out of the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty. To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material Authorization (RMA). Once obtained, send the RMA along with the defective part or goods, transportation prepaid, to: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56001 USA THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. CONDUX ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY. CONDUX WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
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Condux International, Inc.
P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: [email protected] © Copyright 2006, Condux International, Inc. Printed in USA Literature Part Number: 08763499 Revision Number: 1.1
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USER'S GUIDE & SAFETY MANUAL
USER'S GUIDE & SAFETY MANUAL
WDR505 Underground Pulling Trailer
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Important Safety Notice Read and understand all procedures and safety instructions before using a Condux Underground Pulling Trailers. Observe all safety information on this page and note specific safety requirements as explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.
ADVERTENCIA: Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud. no comprende las instrucciones favor de consultarle a su jefe.
Save this user’s guide for future reference.
COMMUNICATIONS WITH THE MANUFACTURER: For information related to the machine (use, maintenance, spare parts) always-state model number, manufacturing Year and Order. This date can be found on the parts identification label. Manufacturer: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56002-0247 1-507-387-6576 Fax 1-507-387-1442 E-mail: [email protected]
If you have questions on: SAFETY - OPERATIONS - APPLICATIONS CALL 1-800-533-2077 2
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Table of Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 A. Operational Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 B. Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 C. Noise Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 A. Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 B. Emergency Stop Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 C. Periodic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 D. Cautions & Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 E. Pulling Rope Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 F. Rotating Component Pinch-Point Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 G. Crushing Injury when Loading or Unloading Rope or Conductor Reels . . . . . . . . . . . .8 H. Electrostatic Discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 I. Inhalation Engine Exhausting Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 4 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 A. Machine Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 B. Packing for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 C. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 D. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 5 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 A. Positioning the Trailer & Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 B. Stabilize Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 C. Start Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 D. Payout Winch Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 E. Prepare for Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 F. Electronic Control Box (ECB) Set-up (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 G. Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 H. Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 A. General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 B. Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 C. Suggested Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 D. Hydraulic Circuit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 E. Reduction Unit and Reel Winder Negative Brake Maintenance . . . . . . . . . . . . . . . . . .14 F. Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 G. Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 H. Electronics Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 I. Summary Table for Ordinary Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 J. Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Troubleshooting 7 8 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 A. Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 B. Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 C. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 D. Suggested Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 E. Parts Breakdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 9 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 10 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
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www.comstarsupply.com
General Information PRODUCT DESCRIPTION
The WDR505 pulling trailer provides up to 11,240 lbs. of pulling force and a max speed of 219 ft/min. It comes equipped with a digital meter counter, hydraulic dynamometer with set point and automatic control of the maximum pull, a noise reduction kit, as well as 1,640 feet of anti-twist rope a key feature. Anti-twist rope offers high flexibility, complete stability to rotation and increased efficiency during pulling operation. An optional Electronic Control Box to monitor pulling speeds and tension is available, as well as an extension arm with multiple pulling positions to accommodate most applications. Condux International manufactures a complete line of cable installation tools and equipment. SAFETY INFORMATION • Only trained and qualified operators should use this machine. • Qualified operators are those persons who have received training from the machine owner’s company or, alternatively, from the manufacturer. • This machine must be used only for the work it was designed for. • This machine should not be used with unauthorized personnel on the work site. • For any questions regarding operation, function, maintenance, etc., contact the After-sales Service of the manufacturer. OPERATOR INFORMATION • Operators must be aware of all local, state and federal safety regulations governing the use of this equipment. • Operators must wear suitable clothing to reduce the possibility of entanglement in the machine’s moving parts. They should avoid the wearing of chains, and other jewelry for the same reason. • Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.). • Operators must carefully follow hazard related instructions contained in this instruction manual or indicated on the machine. • This machine’s work area should be free as possible of oil or other liquid spills as well as materials or equipment that may be considered as an obstacle to proper operation. • The operator must absolutely avoid the direct inhalation of the system’s engine exhaust gas. GENERAL MAINTENANCE INFORMATION
4
• It is absolutely forbidden to carry out any maintenance, or adjust any settings on this machine while pulling (except for those indicated in this manual). • Before carrying out any maintenance stop the engine (except for those instances indicated otherwise in this manual) and wait till the system components subject to heating have cooled sufficiently • All the maintenance performed on this machine must be carried out on a level surface and while the system is not under load. • Authorized and trained personnel must perform all of the maintenance, both scheduled maintenance and repair. Authorized and trained personnel are those persons who have received training on the maintenance of this equipment from the machine owner’s company or, as alternative, from the manufacturer. • Maintenance personnel must wear suitable clothes to reduce the possibility of entanglement in the machine’s moving parts. They should avoid the wearing of chains, and other jewelry for the same reason. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
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• Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.). • All maintenance operations, both scheduled and repair, must be carried out per the instructions included in this manual or following technical instructions provided by the manufacturer. Failure to follow these instructions relieves the manufacturer from any responsibility and voids their warranty. MACHINE USAGE The machine must not be used: • For lifting persons and/or goods • In a location where the machine can not be positioned and anchored in a proper way • In areas with brush or other materials that can be easily set on fire • In closed/unventilated sites or those poorly ventilated (tunnel or similar) • At sites where fuels or explosives are present • For structure demolition • For the pulling of elastic elements • With ropes or joints having a bigger diameter than that specified in this manual • With over-ridden or broken safety system devices • For handling trucks or other movable equipment RESPONSIBILITY Use of the machine in situations different from those indicated in paragraph 2.3 (Typology and using field), or those not described in this manual, is to be considered extremely dangerous and/or forbidden. Persons not using recommended restraints cause a situation of improper use, and relieve the manufacturer from any responsibility for accidents, injuries to persons or damage to property. The manufacturer’s warranty is also voided. Similarly the manufacturer’s responsibility ends when the following situations occur: • Tampering and/or modifying of the system without the manufacturer’s written acceptance (in this case the operator becomes the manufacturer assuming all obligations and responsibilities, both civil and penal). • The use of non-original spare parts. • Poor maintenance. • Use with disconnected or over-ridden safety devices. • For the connection to machine and/or plans not produced and not directly authorized by the manufacturer in a written acceptance. OPERATORS MANUAL • Information contained in this manual applies to all the operators charged with the use and/or the maintenance of the machine. • This instruction manual is not a training manual. • Before using the machine the job site supervisor and the operators must read this instruction manual. • The supervisor is obliged to inform all operators about the instructions contained in this manual. • All operators user must carefully follow the instructions contained in this manual. • Before using the machine the operator must know the positions and the operation of all the controls. • The job site supervisor must verify that the instructions contained in this manual are applied. • This instruction manual must be kept with the machine, for the entire life of the machine, so it is available to all potential users and operators. • The instruction manual must be kept in a sheltered and dry place. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
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Technical Specifications
The Condux WDR505 Hydraulic Underground Pulling Trailer provides up to 9,000 lbs of continuous pulling force. Designed for installing underground cable, the WDR-505 is completely self-contained and transports easily from jobsite to jobsite. Industry leading features like antiwist rope and modular extension arms make the WDR-505 the most advanced puller in the market today. An advanced electronic information system is also available for monitoring and documenting vital pulling functions. GENERAL SPECIFICATIONS PULLER MAX LINE PULL, POUNDS
11,250
SPEED AT CONTINUOUS PULL, POUNDS
9,000
HIGH SPEED CONTINUOUS PULL, POUNDS
2,250
PULLING SPEED FEET PER MINUTE
0–219
BULL WHEEL DIA., INCHES
13
MAX ROPE DIA., INCHES
9/16
FEET OF ROPE
2,300
ENGINE TYPE
DIESEL 46
HORSEPOWER ELECTRICAL SYSTEM
12 Volt
A. OPERATIONAL CONDITIONS Temperature: from -10°C to +40°C. Relevant moisture: from 30% to 90% ± 5%. Weather conditions: any (in line with working conditions). Natural and/or artificial lighting of the working site. B. HYDRAULIC OIL When using the machine always keep in mind operating conditions and their effect on the possibility of your exceeding the following temperature limits for the system’s hydraulic oil. TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C) Hydraulic oil viscosity
Working condition
ATF oil
VG 22
VG 32
VG 46
VG 68
Minimum temperature running in neutral position
-15
-21
-14
-7
-1
Minimum temperature running in full load
19
8
16
24
32
Maximum temperature running in full load
66
48
57
67
76
Maximum temperature running in neutral position
84
63
73
83
93
For additional information concerning the hydraulic oil, see chapter “Maintenance” and the attached comparative table of the oils used on the machine. C. NOISE EMISSION Level of acoustic power (2000/14/CE) LwA = 102 dB(A) Maximim sound pressure level to the operator seat (ISO 11202 – December 1995) Lep = 83 dB(A)
6
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Safety Information
3.
3.
A. SAFETY DEVICES
Machine has been equipped with the following safety devices: • A load-limiting device that automatically stops the engine once the max. pre-set load value has been exceeded • A mechanical negative safety brake that stops all movement if hydraulic pressure is lost • Where possible, guards and covers are provided to protect personnel from moving parts
!DANGER: it is absolutely forbidden to use this machine with protective guards removed or with damaged or disconnected safety devices. B. EMERGENCY STOP DEVICE An emergency stop button is provided (Figure 1) on the control panel. Pushing it immediately stops the engine.
!CAUTION: Use of the emergency stop is ONLY recommended in emergency situations. It is NOT recommended to use the emergency stop system for normal shut down of the system. C. PERIODIC OPERATIONS Proper functioning of safety systems should be verified daily.
!CAUTION: Any customer alterations to the provided safely devices relieves the manufacturer of any responsibility Figure 1. Emergency Stop Button for any resulting damage of property or injury to personnel. D. CAUTIONS & WARNINGS When operating this machine users must be aware of other risks associated with the work for which the machine is intended.
E. PULLING ROPE FAILURE Obviously this will cause uncontrolled movement of the entire machine. Both this and the danger then presented by the pulling rope and/or conductor can cause serious injury or death. To reduce operator exposure to these dangers owners must: • Regularly check the rope and replace it as soon as defects or signs of wear are detected • Assume only the recommended operation positions indicated in this manual
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
F. ROTATING COMPONENT PINCH-POINT HAZARDS Due to the nature of the work being performed and important system functionality, it is not possible to fully guard all rotating components. To minimize risks operators must: • Avoid any contact with the machine’s rotating components • Follow the anchoring instructions described in this manual • Follow all recommendations in this manual regarding the use of personal safety equipment
G. CRUSHING INJURY WHEN LOADING OR UNLOADING ROPE OR CONDUCTOR REELS Operators must know the proper methods for executing these tasks and should be trained to do them properly.
H. ELECTROSTATIC DISCHARGES To reduce the risk presented by static electric charge build up in the ropes and conductors during pulling operations, the machine must be properly grounded. To minimize these risks operators must: • Be trained in, and apply, the proper methods used to ground the machine during before using the machine.
I. INHALATION ENGINE EXHAUSTING GAS To minimize these risks operators must: • Assume the proper operating position during operation and use appropriate safety equipment as needed
8
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Transporting A. MACHINE LIFTING
For machine lifting use only devices (overhead traveling cranes, lift trucks, ropes, cables, hooks, etc.) with a capacity equal to the weight to be lifted. Personel should not be on the machine when it is lifted.
!DANGER: Failure to follow the recommendations in this section may create a dangerous situation and/or damage to the machine. The manufacturer’s warranty may also become void as a result.
3.
4.
B. PACKAGING FOR SHIPMENT Transport by land by truck Certain surfaces may be protected by cardboard and/or plywood and/or polyethylene film. To prevent movement, use nailed wheel chocks. Attach the machine to the floor of a truck box or trailer using chains and hooks at the attachment points provided. C. UNPACKING When receiving the machine verify the condition of the package; immediately notify the transportation company and the manufacturer (use photos whenever possible) of any damage that may have occurred during shipment. Verify that the supplied product matches that which was ordered; immediately advise the manufacturer if there is a discrepancy. Use caution when unpacking to avoid damaging the product.
!CAUTION: Disposal of all packaging materials must be in accordance with local regulations. D. TOWING This machine is designed for towing at highway speeds. No personnel may ride on the machine at any time while towing the machine at ANY speed.
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
5.
5.
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Operating Procedures
It is essential that the Underground Pulling Trailer be properly set up before operation. Using the following procedure will allow the unit to be set up in a short period of time and yield optimum performance.
A. POSITIONING THE TRAILER & LOWER BOOM Position the WDR 505 Puller within an approximate boom arm reach of the manhole or duct bank. After trailer is positioned, lower boom arm. NOTE: It may be necessary to payout a small amount of winch line (releasing it from the boom) first to allow the boom to be lowered. If so please refer to Steps C and D before proceeding. Remove the traveling pin and carefully lower the boom to the position desired for pulling operations (Figure 2). Once in position lock the boom in place with the pin (Figure 3).
Figure 2. Remove Traveling Pin
Figure 3. Lock Boom in Place
Now that the boom is in place, minor adjustments in the puller’s position can be made if necessary for optimum working alignment.
B. STABILIZE TRAILER After the WDR 505 is properly positioned, place wheel chocks to prevent trailer movement. NOTE: The trailer may be disconnected from the tow vehicle or left connected depending on specific site conditions. After placing wheel chocks, stabilize the trailer using three of the five supplied adjustable leveling jacks. Place three jacks in the jack mount locations on the trailer. Raise and lower jacks by rotating crank handle (Figure 4). Place two jacks on the boom arm and adjust jacks until the boom arm is level to the ground (Figure 5). 10
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Figure 4. Rotating Crank Handle Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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Figure 5. Boom Arm Level to the Ground
C. START PULLER Open control panel on side of WDR 505 and secure. Start the engine by holding the glow plug rocker switch unit the glow plug indicator light goes out (Figure 6). Turn the ignition key while holding the glow plug rocker switch until the OK light comes on (Figure 7). Adjust the throttle so the engine runs at a medium RPM.
Figure 7. Turn Ingition Key while Holding Rocker Switch
Figure 6. Hold Glow Plug Rocker Switch
D. PAYOUT WINCH LINE Payout the winch line by pushing the winch line joystick up. The joystick is infinitely variable so payout speed can be varied by the degree to which the joystick is moved. IMPORTANT: Always keep tension on the winch line when paying it out to prevent slack from developing in bull wheel. In typical applications, the winch line will need to be paid out to reach the work area first, i.e. manhole, duct bank, etc. Then prepped for pullback, ie, pulled through duct bank with a pulling rope or tape or installed with a Condux Winch Line Blower. 5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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1-866-326-6782
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E. PREPARE FOR PULLBACK Verify that reel winder pressure gauge is reading between 580 and 870 PSI. If the gauge is reading higher or lower adjust by turning the pressure adjust knob until pressure reads between 580 and 870 (Figure 8). Adjust Maximum Tension Limiter to desired maximum pulling tension value (measured in tons) by inserting the black removable knob into the center of the large dial. Press down on the block knob and rotate until the large red needed is adjusted to the desire value. This will be the maximum pulling force the machine will exert. Once the limit is reached the entire system will shut down and a warning sound will be activated. (Figure 9).
Figure 9. Adjust Maximum Tension Limiter
Figure 8. Verify Reel Winder Pressure Gauge Set hydraulic fluid cooling fan. In the manual mode the fan will remain on at all times. In automatic mode the fan will only come on when the system reaches a temperature of 122°F (Figure 10). NOTE: It is recommended to keep the fan in manual mode if the air temperature is 85 degrees or higher. For automatic mode, turn the fan switch to the (circle symbol) position. For manual mode, switch fan selector to the (circle w/ line symbol) position. NOTE: The red fan indicator light will be lit when fan is in operation.
Figure 10. Set Hydraulic Fluid Cooling Fan
F. ELECTRONIC CONTROL BOX (ECB) SET-UP (OPTIONAL) If the WDR 505 is equipped with an ECB, set ECB parameters at this time. Refer to WDR 505 Quick Reference Guide Section - DLR100 Programming and Set Up for ECB set up instructions.
12
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
G. PULLBACK To start pullback, pull winch line joystick down. The speed of the pullback can be increased by increasing the throttle. During pullback make sure to monitor pull force and speed.
H. SHUT DOWN At the end of the pull, relieve pulling rope tension using the control lever. Turn off ignition key.
Maintenance
3.
6.
A. GENERAL PROCEDURES !CAUTION: Any customer repairs not authorized by the manufacturer relieves the manufacturer of any responsibility for any resulting damage of property or injury to personnel. B. FLUID LEVELS Due to safety and/or regulatory reasons, this machine may arrive without hydraulic oil and fuel. Fill the levels as per the following table: Fluids
Quantity
Hydraulic oil level (table 1, pos. 1)
100 l – 26.4 gal
Engine oil level (see enclosed engine booklet) Fuel level (table 1, pos. 4)
28 l – 8 gal
Negative brake for bull-wheel oil level (table 1, pos. 8)
0.3 l – 0.08 gal
Negative brake for reel winder oil level (table 2, pos. 3)
0.4 l – 0.1 gal
!CAUTION: Not filling fluids to those levels specified above will cause serious damage to system components and voids all product warranties. !DANGER: Purposely ingesting hydraulic liquids, fuels and cooling liquids is potentially lethal. C. SUGGESTED LUBRICANTS The manufacturer tests the machine with the following oils and lubricants: hydraulic circuit and negative brake: IP HYDRUS OIL 46 (ISO VG 46). Alternates must be chosen from the enclosed table “SUGGESTED LUBRICANTS”. It is possible to use different products, but they must have the same characteristics and ISO specifications.
!CAUTION: The use of lubricants not in conformity with the technical specifications indicated in the referenced table can seriously damage the machine, its components and voids all product warranties.
5 Blue Heron Drive
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!DANGER: Let the engine cool prior to performing any maintenance, or before refueling. D. HYDRAULIC CIRCUIT MAINTENANCE Change the hydraulic oil after 500 working hours, then every 1500 hours (or at least annually). To drain the hydraulic oil remove the hydraulic tank’s drain plug (table 2, pos. 6).
!DANGER: Allow the hydraulic oil to completely cool before removing it. Always use suitable safety gear (gloves, etc.). !CAUTION: Disposal of all drained system oils and fluids must be in accordance with local regulations. Fill the hydraulic oil using the filler spout designated on table 1, pos. 2.
!CAUTION: insure that no foreign matter enters the system along with the oil; if possible filter the oil with a 10 µm filter. Replace the filter cartridge after 500 working hours and then, every 1500 hours (or at least annually). Check that the hydraulic oil filter lamp lights only during start-up. If lit ant any other time it indicates that the hydraulic oil filter needs replacing. For further maintenance instructions on the hydraulic components (pumps and motors) refer to the enclosed documentation.
E. REDUCTION UNIT AND REEL WINDER NEGATIVE BRAKE MAINTENANCE Change the oil of the bull-wheel reduction unit and negative brake (table 1, pos. 8) and of the reel winder brake after 50 working hours and, thereafter, every 500 hours (or at least annually). To drain the reduction unit and negative brake’s oil use the plugs on the lower part of their housings.
!DANGER: Allow the oil to completely cool before removing it. Always use suitable safety gear (gloves, etc.). !CAUTION: Disposal of all drained system oils and fluids must be in accordance with local regulations.
14
5 Blue Heron Drive
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(610) 831-5020
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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Fill the oil into the reduction unit and in the negative brakes using the proper fill spout
!CAUTION: insure that no foreign matter enters the system along with the oil. For further maintenance instructions on these subsystems (reduction gear, negative brakes) refer to the enclosed documentation.
F. OIL MAINTENANCE At least once a year, or as frequently as required, using compressed air, blow all debris from the fins of the oil coolers.
!CAUTION: Personnel cleaning the oil coolers as per above should wear all required personal protective gear, including a respirator. G. GREASING The crown gear of the bull-wheels should be greased 2-3 times per day using the proper grease. Grease all the other points not automatically lubricated daily. Use IP ATHESIA GR2 (ISO XBCEA 2) grease or equivalent from the enclosed “SUGGESTED LUBRICANTS” table.
H. ELECTRONICS NOTE When cleaning the machine, avoid direct spraying of water or steam on electronic components or the control panel. For the other periodic operations refer to the summary table for the ordinary maintenance (see next page).
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Comstar Supply,
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I. SUMMARY TABLE FOR ORDINARY MAINTENANCE This table lists the recommended service intervals for the systems noted. Part
Object
Diesel engine
Engine oil
Interval Daily
50 h
CL
ST
Cooling liquid
CL
ST VF
Air filter Fuel
Bull-wheel gear box
Reel winder
ST
CL
Fuel filter
ST
Hydraulic oil
CL
ST1
ST(*)
Filter
VF
ST1
ST(*)
Oil
CL
ST1
ST(*)
CL
ST1
ST(*)
CL
ST1
ST(*)
Bull-wheel negative Oil brake Reel winder negative Oil brake Bull-wheels greasing circuit
1500 h
ST
Oil filter
Hydraulic circuit
250 h 500 h
Gears
GR
Chain transmission Level winder screw
GR GR
Pawl
VF
Legend: CL Check the level (and possible filling up) GR Grease ST Replace ST1 Replace (only for the first time) VF Check (*) Or in any case every year
J. EXTENDED STORAGE When an extended storage period is anticipated (two months or more) coat external parts with waterproof protectant. During the storage period, start the machine at least once every two months and let the engine idle for approx. one hour. Do this so that oil enters the hydraulic system and coats all gaskets, o-rings, etc. The machine should be stored under a roof. Do not tarp the machine as excess moisture may collect under it and cause damage to the system. If the machine is stored for a year or more, replace the hydraulic circuit’s oil and filters prior to startup.
16
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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Troubleshooting Guide PROBLEM:
CAUSE:
SOLUTION:
Burned fuse
Replace
Ran down battery
Recharge or replace
Disconnected contacts of the The diesel engine starter ignition system / starter doesn’t work. Oxidised contacts of the ignition system / starter
Diesel engine doesn’t work.
3.
7.
Reconnect Clean or spray with a suitable vaporiser
Starter out of order
Replace / Technical assistance
The emergency pushbutton is pushed in locked position
Release
The ignition push-button is not pushed
Push the ignition pushbutton and keep it pushed till the engine starts
Wait for the turning off The pre-heating glow plugs of the pre-heating glow warning light isn’t turned off plugs warning light Fuel problem
Check the fuel level in the tank Check the fuel filter Add engine oil
Check of the engine oil pressure
Defective sensor– check contacts / replace Engine anomaly – technical assistance
Diesel engine turns off when releasing the ignition push-button.
Add cooling liquid Defective sensor– Check of the engine cooling check contacts / liquid temperature replace Engine anomaly – technical assistance
The feeding pressure is lower than 24 bar – 340psi
Clogged hydraulic oil filter
Replace
Defective pump
Technical assistance
Diesel engine doesn’t increase rpm
Disconnected accelerator cable
Verify and if necessary replace
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
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Comstar Supply,
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PROBLEM:
CAUSE:
SOLUTION:
Hydraulic oil temperature too low
Wait for a few minutes for heating the oil without speed up the diesel engine. It is possible to reduce the oil heating time by turning off the fan of the hydraulic oil radiator (if turned on) and by closing the reel winder valve at 50 bar – 725 psi
The oil is too thick as regards as the environmental conditions
Use oil with lower viscosity as per the indications in the instruction manual
Clogged hydraulic oil filter
Replace
Disconnect joy-stick contacts
Reconnect
Oxidised joy-stick contacts
Clean or spray with a suitable vaporiser
The clogged filter warning light turns on.
Verify the intervention and the electric contacts of the negative brake opening solenoid valve
When starting the control lever the bullwheels don’t work.
The negative brake on the reduction unit doesn’t open Disassemble the brake and verify if the brake discs are in locking position – technical assistance
The electronic card for pump control doesn’t work
Defective pump servo control
18
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Verify the ignition of the green and red LEDS on the card by moving the joy-stick – if the LEDS don’t turn on, replace the fuse on the card or verify the joy-stick potentiometer – technical assistance Verify the electric contacts – technical assistance
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Comstar Supply,
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INC
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1-866-326-6782 PROBLEM:
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CAUSE:
SOLUTION:
Increase the reel winder pressure Reel winder pressure not sufficient
Replace the adjusting valve for the reel winder pressure Reel winder pump problem – technical assistance
When moving the control lever, the bullwheels rotate but the rope doesn’t move – slips on the bullwheels. The negative brake on the reel winder doesn’t open
Verify the intervention and the electric contacts of the negative brake opening solenoid valve Disassemble the brake and verify if the brake discs are in locking position – technical assistance Add engine oil
Check of the engine oil pressure
Defective sensor – check contacts / replace Engine anomaly – technical assistance Add cooling liquid
Defective sensor Check of the engine cooling – check contacts / Diesel engine turns off liquid temperature replace during operations. Engine overheating – technical assistance The max. pre-set pull has been reached
Intervene of the pull limiting device on the dynamometer Increase the intervene threshold of the pull limiting device Operation of the emergency Release push-button
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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1-866-326-6782
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PROBLEM:
The machine doesn’t reach the max. pull performances.
CAUSE:
SOLUTION:
Diesel engine rpm not sufficient
Speed up the engine
Diesel engine decreases rpm and turns off
Decrease the control lever capacity
Excessive hydraulic oil temperature
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm Check the fuel filter
Insufficient fuel feeding at diesel engine
The machine doesn’t increase speed.
Fuel feeding system to be adjusted – Technical service
Diesel engine rpm not sufficient
Speed up the engine
Diesel engine decreases rpm and turns off
Decrease the control lever capacity – the applied pull doesn’t allow to reach higher speed
Excessive hydraulic oil temperature
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm Check the fuel filter
Insufficient fuel feeding at diesel engine
20
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fuel feeding system to be adjusted – Technical service
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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1-866-326-6782 PROBLEM:
www.comstarsupply.com
CAUSE:
SOLUTION:
The fan of the hydraulic oil doesn’t work
5 Blue Heron Drive
Verify the electric contact of the ventilator ignition selector on the control panel
Overused machine
Wait for a few minutes for cooling the oil. It is possible to reduce the oil cooling time by turning on the fan of the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm
Anticipated closing of the negative brake
Verify the control by means of the suitable trimmer on the electronic card
Hydraulic pump with defective zero setting
Carry out the hydraulic and mechanic zero setting – technical assistance
Excessive hydraulic oil temperature.
An anomalous stop happens when returning to center position with the control lever
Verify the electric contact of the temperature bulb on the radiator
Collegeville, PA 19426
(610) 831-5020
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Fax: (610) 831-5012
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11.
8.
www.comstarsupply.com
Appendices QUICK REF. SERVICE & PARTS LIST A. HYDRAULIC OIL FILTERS Manufacturer
Part Number
Quantity
Vendor
Alternative Vendors
MP Filtri
CS-150-P10-A
1
Motion Industries
Filtrec A121C10
B. ENGINE AIR FILTER Manufacturer
Part Number
Quantity
Vendor
Cummins
1236-01-00
1
Cummins
C. ENGINE Manufacturer
Engine Model
Cummins
A2000
Engine Service Part
Part Number
Oil filter
LF-16034
Fuel Filter
FS-1235
Fan Belt
4900271
Lubricants
Specification (*)
Engine Oil
SAE 15w-40
Hyd. Fluid
ISO 32
Gear Lube
ISO 150
General Grease
EP 2
* See Engine Manual or Recommended Lubricants chart for temperature variances. Ø All filters, parts, and service for the engine can be found at your local Cummins distributor. Your local distributor can be found at: Cummins, Inc. 1-800-DIESELS (1-800-343-7357) USA & Canada only
22
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
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5 Blue Heron Drive
Collegeville, PA 19426
DONAX TM
ATF 200
MOBIL
SHELL
DEXRON II
VG 33-VG 39
UNIVERSAL OIL ATF
CASTROL
(ISO 3448)
VISCOSITY
TYPE
TELLUS 22
TELLUS 32
DTE 24
HYSPIN AWS 32
HYSPIN AWS22
DTE 22
VG32
-10°C
-30°C
VG22
COLD
ARCTIC
VG68
TROPICAL 40°C+
VG100
-30°C VG150
-10âC
COLD
TELLUS 46
DTE 25
HYSPIN AWS 46
TELLUS 68
DTE 26
HYSPIN AWS 68
OMALA 150
MOBILGEAR 629
MOBILGEAR 627 OMALA 100
ALPHA SP 150
ALPHA SP 100
OMALA 220
MOBILGEAR 630
ALPHA SP 220
VG220
30°C
TEMPERATE
GEAR BOX
SUGGESTED GENERAL MANUFACTURERS
VG46
30âC
TEMPERATE ARCTIC
SUGGESTED LUBRICANTS
HYDRAULIC CIRCUIT AND STATIONARY BRAKE
D. SUGGESTED LUBRICANTS
OMALA 320
MOBILGEAR 632
ALPHA SP 320
VG320
40°C+
TROPICAL
SUPERGREASE EP 2
MOBILUX EP 2
SUPERGREASE 2
EP 2
EP TYPE
GREASE
Comstar Supply,
Think Cable... Think Comstar
INC
1-866-326-6782 www.comstarsupply.com
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
www.comstarsupply.com
(610) 831-5020
23 Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
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1-866-326-6782
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C. PARTS BREAKDOWN
24
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
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Notes
5 Blue Heron Drive
3.
9.
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
25
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
26
5 Blue Heron Drive
www.comstarsupply.com
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Warranty Information
3.
10.
A. FACTORY ASSISTANCE
Condux International can provide further advice regarding any problems with the installation, service, assembly, or disassembly of the Condux Underground Puller. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Condux Underground Puller can be returned to the factory at any time for service or repair; however, a Return Material Authorization (RMA) must be obtained from Condux before shipping. Condux will not accept returned items without an RMA.
B. LIMITED WARRANTY Condux International, Inc. extends the following warranty to the original purchaser of these goods for use, subject to the qualifications indicated: Condux International, Incorporated warrants to the original purchaser for use that the goods or any component thereof manufactured by Condux International will be free from defects in workmanship for the period of one year from the date of purchase, provided such goods are installed, maintained, and used in accordance with Condux’s written instructions. Components not manufactured by Condux International but used within the assembly provided by Condux International are subject to the warranty period as specified by the individual manufacturer of said component, provided such goods are installed, maintained, and used in accordance with Condux’s and the original manufacturer’s written instructions. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising out of the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty. To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material Authorization (RMA). Once obtained, send the RMA along with the defective part or goods, transportation prepaid, to: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56001 USA THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. CONDUX ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY. CONDUX WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
27
Comstar Supply,
5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012
INC
Think Cable... Think Comstar
1-866-326-6782
www.comstarsupply.com
Condux International, Inc.
P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: [email protected] © Copyright 2006, Condux International, Inc. Printed in USA Literature Part Number: 08763499 Revision Number: 1.1
5 Blue Heron Drive
Collegeville, PA 19426
(610) 831-5020
www.comstarsupply.com
Fax: (610) 831-5012
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